You could try scanning for codes. 1990 is the early TCM so it might have a stored code. With the early TCM you can't count on the OD off light flashing.
Skipping third gear could be multiple issues. Faulty TPS, faulty VSS, faulty TRS or faulty tach sensor. Take a look at the ABS sensor too...
Don't worry about code 65. You didn't push the OD OFF button at the right time.
Code 23 is the problem. The TPS is out of range, or needs to be replaced.
Rubber gaskets are reusable. Clean it up good. If you see any nicks or damage get a new one.
After you clean up the tranny pan. Take a straight edge and check the rails at the bolt holes. If you have any waves straighten them out. This will keep your gasket from leaking.
If you shake the converter you will here a rattle because the clutch has no pressure.
Most likely the converter is shot. It shouldn't make that funky sound when you spin it.
Ford realized this hose was not needed. It never did what it was intended to do.So it was discontinued.
You can delete this hose. The tranny will heat up faster than the coolant so it never worked as intended. Ford discontinued this part for that reason.
You will need both copies of the ATSG guide for the E4OD. First copy covers the basic E4. What you have. The second is the update manual. It will cover the update to the 98 model year.
The manual will have the special tool list in the text.
A billet cover is a plus, but they too could be built with not so great parts.
You can get a single disk (stock) with a billet cover. Single disk converters are what gives the E4 a bad name.
Code 62 is a converter code. Clutch failed to lock. This because it is starting in a higher gear.
Seeing how you have checked the solenoid pack, and is good.
Time to check the accumulator body for stuck or broken springs. D2, 2-3 and 3-4 shift valves.
Something is up with the converter. I would do a pressure test on the tranny just to check it out.
Most likely the tranny is fine. The converter on the other hand is on its last leg. If you were to remove the converter and look at the cover. I bet you will see the blue ring of death. This is...
The 95 E4OD will work in your 90. The only changes are the torque converter and solenoid pack.
Almost forgot the manual lever. This will need to be changed. Pull the manual lever from the 90, and swap it to you 95 tranny. After 92 the tranny uses a cable actuator to select the gears. Pre 92...
The converter will leak down without a check valve.
If you are upgrading to 3/8" lines. You a 4R100 bypass. It will give you the required valve and 3/8" parts.
$3000- $3500 is a bit high for a C6, unless it is built for drag racing. :D
As for the kick down rod, you don't really need it. Manual shift to second when passing.
95 was the upgrade year to make the E4 handle more power. One of the changes was the solenoid pack. The pack connector needs to be repinned to operate a pre 95 E4.
There are many good upgrades for the E4. Depend on how crazy of a build you want to do, or how much coin you want to drop...
Sometimes they break, sometimes they bend. Depends on how hard the manual lever was thrown.
Most of the time the roller jumps over the manual lever detent.
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